DesignforManufacture

(DFM)
Introduction GeneralGuidance
DFMIntroduction

Manufacturingsystemstypicallycomprisealargenumberofprocessesor
stages

Eachaffectproductcost,productquality,andproductivityoftheoverall
system,eitherindividuallyorcollectively.

Interactionsbetweenthefacetsofthemanufacturingsystemarecomplexso
decisionsconcerningoneaspectmayhaveramificationsthatextendtothe
others.

2
ManufacturingInteractions

Product
Design
Material
MaterialHandling Selection&
Processing

Purchased
QualityControl Components

Assembly
 CostContributors?
Whatfactorscontributetotheoverallcostofa
product?
CostContributors?
 Designersneedto:

Designproductformanufacturebythemostappropriate
processesintermsof:
Quality
Cost
Availability.

Considerassemblyrequirements fundamentalto
manufactureofmostcomponents.
DFMGuidlines
1. MinimisePartCount
2. ModularDesign
3. MinimisePartVariations
4. MultifunctionalParts
5. PartsforMultipleUse
DFMGuidelines

1.Minimisethepartscount
Eliminatingpartsresultsinsavings,fewerpartsmeanless:
time,
drawings,
partnumbers,
records,
purchaseorders,
vendors.
DFMGuidelines

1.Minimisethepartscount (contd)
Apartthatiseliminatedcosts:
nothingtomake,
nothingtoassemble,
nothingtomove,
nothingtostore,
nothingtoclean
nothingtoinspect.
DFMGuidelines

1.Minimisethepartscount (contd)
Ausefulwaytominimisepartsistosetaminimum
partcountattheconceptualdesignstageand/or
considercombiningtwoormorepartsintoone.
DFMGuidelines

1.Minimisethepartscount (contd)
Partstoconsiderforremovalorforcombiningare
partswhichneed:
norelativemotion
nosubsequentadjustment
noservicingorreparability
nodifferenceinmaterials
DFMGuidelines

1.Minimisethepartscount (contd)

However,takecare!Removingtoomanypartsor
inappropriatepartscanaddcostsiftheremainingparts
becometooheavyortheirdesignandshapebecomes
toocomplex.
DFMGuidelines
PartsReductionExample
DFMGuidelines
PartsReductionExample contd
Twodifferenttypesofsprocketandgearwheel:

a)Requiresassembly:ismadeofsteel producedbymachining
i.e.individualteetharecut,i.e.mustdivideintotwoelements
duetoproductiontechnique.

b) Requiresnoassembly:producedfromsinteredmetal teeth
sinteredinaccordancewiththerequiredtoleranceandsurface
quality;advantages nowastematerial,shortprocessingtime
andnoassembly.
DFMGuidelines

1.Minimisethepartscountcontd

Recognisedmethodforreducingpartscountisthe
ValueEngineeringMethod(VEM)

Aim:Toincreaseormaintainthevalueofaproductto
thepurchaserwhilereducingitscosttothe
manufacturer.
DFMGuidelines

1.Minimisethepartscountcontd
ValueEngineeringMethodprocedure:
Listseparatecomponentsoftheproduct,andidentify
thefunctionofeachcomponent
Determinethevaluesoftheidentifiedfunctions
Determinethecostsofthecomponents
Searchforwaysofreducingcostwithoutreducingvalue,
oraddingvaluewithoutaddingcost
Evaluatealternativesandselectimprovements.
DFMGuidelines

2.Developamodulardesign

Module aselfcontainedcomponent standard

interfacewithothercomponentsinthesystem,e.g.
interchangeablecameralenses,pluginmodulesfor
electronicinstruments.

Modulardesign opportunitytostandardise but

productscanbecustomisedbyusingdifferent
combinationsofstandardmodules.
DFMGuidelines

2.Developamodulardesign
Resistanttoobsolescence newproductscanutilise
someoldmodules especiallyimportantinthe
automotiveindustrywherespeedofchangeisever
increasing.
Benefitsservice andrepairneeds andaidsthefinal
assemblytask.
Majordisadvantagecost manymoreextrafittingsand
interconnectionsmayberequired
DFMGuidelines

3.Minimisepartvariations

Usestandardcomponents preferredsizes standard

partscostlessthanspecials.
Qualityproblemsreducedwhenpartvariationsare
minimised.(e.g.typeofscrewused)
littlejustificationforseveralscrewsizes/typesofmetalina
singlepart.
Reducedpartvariationalsominimisesinformationrequired
bytheproductionsystem.
 DFMGuidelines
4.Designpartstobemultifunctional
Minimisepartscountbydesigningpartstofulfilmore
thanonefunction,e.g.:
designaparttoactasanelectricalconductorandasa
structuralmember
F1Car gearbox/transmissionformspartofchassis
Motorcycleengineformsastressedmemberoftheframe
DFMGuidelines

5.Designpartsformultipleuse
Keytothisapproachistoidentifycandidatesformultiple
use.Oneapproachistosortpartsintotwogroups
consistingof:
partswhichareuniquetoaparticularproduct,
e.g.crankshafts,bearingsetc.
Partsgenerallyneededinallproductsormodels,
e.g.flanges,spacers,shaftsetc.
DFMGuidelines
5.Designpartsformultipleuse
Keytothisapproachistoidentifycandidatesformultipleuse.One
approachistosortpartsintotwogroupsconsistingof:

Divideeachgroupintocategoriesofsimilarparts(partfamilies)
Create Multiusepartsbystandardisingsimilarparts.
Thensequentiallyseektominimisethenumberofpartcategories,
thenumberofvariations withineachcategoryandthenumberof
designfeatures withineachvariation
DFMGuidelines
1. MinimisePartCount
2. ModularDesign
3. MinimisePartVariations
4. MultifunctionalParts
5. PartsforMultipleUse
 DFMGuidelines

6.Designpartsforeaseoffabrication
Requiresthatpartsneedtobe:
Designedusingthe leastcostlymaterial thatjust
satisfiesfunctionalrequirements (includingstyleand
appearance)andminimisesmaterialwasteandcycle
time.
Madebythemostsuitablefabricationprocessavailable
andbeproperlydesignedforthatprocess
Madeusinganearnetshape processwhenever
possible
 DFMGuidelines

6.Designpartsforeaseoffabrication (contd)
Requiresthat:
Secondaryprocesses(machining,painting)areavoided,
byspecifyingtolerances,surfacefinishandmaterial
carefully
Selectingprimaryprocesses(casting,moulding,sintering)
whichmeetcomponentrequirements.
Materials which avoidtheneedforpainting,buffing,
platingetc.shouldbeconsidered.Highermaterialand/or
processcostscanbeacceptediftheyleadtolower
overallproductioncosts.
 DFMGuidelines
7.AvoidSeparateFasteners
Automatedassembly separatefastenersaredifficulttofeed,tend
tojam,requiremonitoringforpresenceandtorqueandrequire
costlyfixtures,partsfeedersetc.
Manualassembly costofdrivingascrewcanbeuptotentimes
thecostofthescrew.
Eliminatefastenersbyusingsnapfitsortabs.
Sometimes,fastenerscannotbeavoidede.g.finalassemblylineof
anautomotiveplantwherescrewsareusedforsecuringandjoining
alargenumberofpartstothecarbody.Strength,andeaseof
adjustment/replacementmakesthemamust.
 DFMGuidelines
7.AvoidSeparateFasteners (contd)

Whereused,costandqualityriskscanbereducedbyminimisingthe
number,sizeandvariationofthefastenersused.
Avoidfastenerswhicharetoolong/shortandwhichneedseparate
washersand/ortappedholes.
Wherefastenersareusedselftappingscrewswithcaptivewashers
arepreferred.
VW coneshapedtippedscrewseventhough18%moreexpensive,because
theygointoholesmoreeasily,especiallyifpartsarenotwellaligned.
Enabledassemblytobesimplifiedsothatthefasteningcouldhedoneby
robots,substantiallyreducingcosts.
Becamesopopularthroughouttheautoindustrythatwithintwoyearsthe
priceofconeshapedscrewshaddroppedtothatofordinaryscrews.
 DFMGuidelines
8.Minimiseassemblydirections
Assembleallpartsfromonedirection.
Extradirectionsmeanwastedtimeandmotion,need
moretransferstations extracostsduetoreliabilityand
qualityrisks
Ideallyinanyassemblyallpartsaddedinatopdown
fashiontocreateaZaxisstack withallpartspositively
locatedastheyareadded.
 DFMGuidelines
9.Maximisecomplianceinassembly
Excessiveassemblyforcerequiredifpartsarenot
identical/perfectlymade.
Requiresappropriateproductdesignwithcompliance
featurese.g.
Generoustapers,chamfersandradii.
Makingoneofthecomponentsoftheproductthepartto
whichotherpartsareaddedtoavoidtheneedforanassembly
fixture&providingarigidlocationsurfaceintheproductitself.
Mayrequiredesignfeaturesthatarenotneededforthe
productfunction.
DFMGuidelines
ComplianceinAssembly Example
 DFMGuidelines

10.MinimiseHandlinginAssembly
Partsshouldbedesignedtoallowtherequiredpositiontobe
achievedeasily.
Morepositionsrequiredinassemblymeansincreasedequipment
expenseandgreaterriskofdefects.Gooddesignmakespartsas
symmetricalasfunctionwillallow
CorrectOrientationofpartscanbeassistedbydesignfeaturesto
helpguideandlocatepartsintorequiredposition featuresmay
notbeneededforproductfunction
Palletisedtraysandkitsaremethodsofsupplyingproperly
orientedpartstotheassemblyline
Foreaseofhandlingavoidflexiblecomponents,userigidgaskets,
circuitboardsinplaceofcableetc.
 DFMGuidelines

10.MinimiseHandlinginAssembly (contd)
Designrulestogivemorefocus include:
Spacingofholesinmachined,cast,stampedparts,to
allowforoneoperationwithouttoolingweakness
thislimitshowcloseholesmaybespaceddueto
strengthinthethinsectionbetweenholes
Avoidgeneralisedstatementsondrawingse.g.
'polishthissurface'ortoolmarksnotpermitted' difficult
formanufacturingpersonneltointerpret
Notesondrawingsshouldbespecificandnotambiguous.
 DFMGuidelines
10.MinimiseHandlinginAssembly (contd)
Designrulestogivemorefocus include:
Dimensions generallyfromspecificpointsor
surfacesonthepart(notfrompointtopoint)aidthe
creationoffixtures,gauges,etc.andminimise
tolerancestacking
Particulardesignrules contd
DFMGuidelines
6. Easeoffabrication
7. Avoidseparatefasteners
8. Minimiseassemblydirections
9. Maximisecomplianceinassembly
10. Minimisehandlinginassembly
 DFMGuidelines
Designrulestogivemorefocus include:
Designingforminimumweight,consistentwith
strengthandrigidityrequirementsensuresa
reductioninmaterialcostsandapossiblereduction
inlabour/toolingcharges
Designingpartssothatmanyoperationscanbe
performedwithoutrepositioningpromotes
accuracyandminimisehandling
 DFMGuidelines
Designrulestogivemorefocus include:
DesigntopermitgeneralpurposetoolingAvoids
specialdies,cuttersetc.Exceptionishighvolume
productionwherespecialtoolingcanbejustified
ToolsandTechniques

ToolsusedbyLucasIndustriesintheProduct
IntroductionManagement(PIM)processinclude:
DesignforAssembly(DFA)
QualityfunctionDeployment(QFD)
FailureModeEffectsAnalysis(FMEA)
DesignofExperiments(DOE)
ToolsandTechniques

1.DesignforAssembly(DFA)
 FunctionalAnalysis 1

Listallcomponents byname&numberonanalysis
chart
Step1 Functionalrequirementofproduct?
Step2 Considerproductaswholeorfunctionalsub
sections? (wholeisbest avoidanceofduplication)
Step3 Identifycategoryofcomponent
AFunctional vitaltoperformancee.g.gear,driveshafts,
adjustingscrew,timingbeltetc.
B Nonfunctional notcriticaltoperformance,e.g.fasteners,
locationfeatures,lockingdevicesetc.
FunctionalAnalysis 2

Startwithmajorfunctionalcomponent consider
matingcomponentsinlogicalprogression
Categorise usingtheFunctionalCriteriaChart
DeterminetheDesignEfficiencyfrom:

Number of A components
E 100%
Total Number of components
NB:Highaspossible minimum60%
BenefitsObtained

Anaveragepartcountreductionof46%and
Anaverageassemblycostreductionof47%.
Implementedunitcostsavingsondirectlabourand
materialcostsonlyarereportedintherange15
35%.
PartsCountReduction(example)
ProcessSelectionDrivers

Productquantity Material/process
compatibility
Equipmentcosts
Toolingcosts Componentformand
dimensions
Processingtimes
Tolerancerequirements
Labourintensityandwork
patterns Surfacefinishneeds
Processsupervision Bulktreatmentandsurface
engineering
Maintenance
Processtocomponent
Energyconsumptionand
variability
otheroverheadcosts
Materialcostsand Processwaste
availability Componentrecycling
CostofDifferentProcess
SimultaneousEngineering
DesignEfficiencyExample
DesignEfficiencyExample

Whatisthefunctionofthe
product?
DesignEfficiencyExample

Partcount?
DesignEfficiencyExample

MakesureyouconsiderALLComponents!
DesignEfficiencyExample

Partcount?
DesignEfficiencyExample